training systems for hydraulics

Training Systems for Hydraulics

2 Training Systems for Hydraulics

Bosch Rexroth AG, 01.2015, R999000178

Training Systems for Hydraulics

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Drive & Control Academy 4

Study topics 7Overview 10On/off hydraulics 12Proportional servo valve technology 31Mobile hydraulics 42Expansion device sets 55Accessories 64

Workstations 67Overview 70WS200 76WS201 82WS290 84Accessories 86- General 86- for WS200 91- for WS290 91

Order examples 93On/off hydraulics 96Proportional servo valve technology 98Mobile hydraulics 100

Components and spare parts 103Components 106- Valves 106- Cylinders, load units, motors 123- Mobile hydraulics 129- Hydraulics accessories 132- Electronics 139- Measurement technology 154

Spare parts 160- for workstations 160- for hydraulic components 168

4 Training Systems for Hydraulics | Drive & Control Academy


Drive & Control Academy

Knowledge the decisive competitive advantage

www.boschrexroth.de/academy

Drive & Control Academy | Training Systems for Hydraulics

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MediaFor further information please visit: www.boschrexroth.de/trainingmedia

The software-based teaching and learning media from Rexroth are characterized by a high practical relevance and are tailored to the training courses and training systems.They include e-learning modules, technology and applications trainer, animations of components and systems and simulation-based learning units. Additionally, they include dictionaries, reference books, manuals for trainers and trainees and various tools.

TrainingFor further information please visit: www.boschrexroth.de/training

New training courses and continuous development of training methods ensure that the knowledge that is transferred is the current state of the art. The methodological repertoire includes classroom training, e-learning, practical training and blended learning, which combines the advantages of face-to-face instruction with e-learning. The principle of proximity to customers is the focus of our training systems.

Knowledge is everythingEmployees' specialist knowledge and expertise provide a crucial advantage for their company on a competitive global market. Under the tutelage of the Drive & Control Academy, Rexroth offers trainees an extensive portfolio of educational products in the field of drive and control technologies, which is solidly rooted in industrial practice.The Drive & Control Academy sets the standard for training, especially when it comes to setting up effective learning systems for customers and employees and education and training institutions to support the acquisition of integrated expertise. Everything we offer is based on the same principles:

State-of-the-art, real-life equipment. Training tailored to specific target groups. Modern training methods

Training systemsFor further information please visit: www.boschrexroth.de/trainingsystems

A training system consists of the workstation, the components contained in the device sets and the project manuals. The training systems provide both novices and advanced trainees with practical knowledge in the fields of hydraulics, pneumatics, electrical drive and control technology, mechatronics and automation. They include industrial series-produced components and have internationally standardized programming languages and open interfaces.

As a leading specialist in drive and control technology worldwide, Bosch Rexroth has a unique level of technological expertise. At the Drive & Control Academy, we pass on our expertise and support in this way tailored training, development and qualification of technical specialists.

6 Training Systems for Hydraulics | Terminology Terminology


Terminology

Term Explanation

Device set A device set is an assembly of components used to carry out practical exercises.

Study topics For a single study topic, it is possible to use more than one device set with the corresponding project manual. You can find the study topics in this catalog: On/off hydraulics, proportional servo valve technology and mobile hydraulics

Workstations Workstations are used for receiving components from the device sets to carry out practical exercises according to the project manuals.

Training systems A training system combines workstations, device sets and project manuals.

Spare parts Spare parts are parts that are installed on components or workstations.

Accessories Accessories are complementary products that can be used optionally.

BIBB German Federal Institute for Vocational Training (Bundesinstitut fr Berufsbildung)

Study topics | Training Systems for Hydraulics

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Study topics

8 Training Systems for Hydraulics | Study topics


Study topics | Training Systems for Hydraulics

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Contents - study topics

Overview of devices and expanded sets 10

On/off hydraulics 12Getting started 12Manual actuation according to BIBB A-H 14Electrical operation according to BIBB A-H and Z1-Z3 18Troubleshooting, manual operation 27Troubleshooting, electrical operation 29Accessories 30

Proportional servo valve technology 31Proportional hydraulics 31Hydraulic control 36Accessories 41

Mobile hydraulics 42Throttle control 42Load-sensing control 46LIFD control 50Accessories 54

Supplementary device sets 55

Accessories 64

10 Training Systems for Hydraulics | Study topics Overview of devices and extension sets


Device sets

Overview of device and extension sets

Study topics | Training Systems for Hydraulics Overview of devices and extension sets

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12 Training Systems for Hydraulics | Study topics On/off hydraulics - getting started according to BIBB A-E3


On/off hydraulics - getting started according to BIBB A-E3

The learning objectives are coordinated with the German Federal Institute for Vocational Training (BIBB) proposed topics. The project tasks are practice-oriented and match very closely orders from industrial and trade customers. The structure is planned according to didactic principles and explains the implementation of individual projects on a step-by-step basis.Delivery includes:

project manuals for instructors and trainees device set with components

Project manuals for instructors and trainees The instructor's guide to imparting know-how is available to instructors and teachers of specific subjects. This project manual contains basic theoretical knowledge and guidance on practice-related project tasks in the field of hydraulic control technology. It contains additional details about projects and information for instructors. The trainee uses the student handbook. This manual is also used to enter measurement results and calculated parameters. Answering of project-related issues rounds off the project exercises.Contents:

theoretical basics on the basis of project exercises a practical introduction to the project exercises (identifying hydraulic

components) commissioning a hydraulic system function and structure of pressure relief valves, hydraulic cylinders

and directional control valves function of throttle check valves and pressure reducing valves

Trainer's manuals Language Mat. no. Book title Type short description Edition no.Trainer's manual On/off hydraulics - getting Started DE

DE R961008759 Schalthydraulik - Erste Schritte MANUAL TW-HY-LH 101DE

DCA-DE000147

Trainer's manual On/off hydraulics - getting Started EN

EN R961008761 On/off hydraulics - getting started

MANUAL TW-HY-LH 101EN

DCA-EN000147

Trainee's manuals Language Mat. no. Book title Type short description Edition no.Trainee's manual On/off hydraulics - getting started DE

DE R961008760 Schalthydraulik - Erste Schritte MANUAL TW-HY-SH 101DE

DCA-DE000148

Trainee's manual On/off hydraulics - getting started EN

EN R961008762 On/off-hydraulics - getting started

MANUAL TW-HY-SH 101EN

DCA-EN000148

No. Exercise topic BIBB exercise01 Identify components A

02 Commissioning A

03 Function of a pressure relief valve

04 Directional valves and hydraulic cylinders B1

05 Load pressure with hydraulic cylinders D1/E1

No. Exercise topic BIBB exercise

06 Supply throttling with hydraulic cylinders D3/E1

07 08

Manipulating the travel velocity E1

09 The effects of discharge throttling (pressure conversion)

10 Pressure reducing valves E3

Comparison of the project exercises of Bosch Rexroth AG with the proposed exercises by the German Federal Institute for Vocational Training (BIBB)

Study topics | Training Systems for Hydraulics On/off hydraulics - getting started according to BIBB A-E3

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Device set for WS200/WS290 On/off hydraulics - getting started

Material number R961008522

Type short description DEVICE SET TS-HS 101-1X

This device set is used to impart the basics of hydraulics based on project work. Only industrial components of size 6 are used that have been specially prepared for use in the training exercises.The device set matches the On/off Hydraulics - Getting Started training manual that deals with BIBB exercises A-E3. The exercises with the listed components can be performed on both the WS200 and WS290 workstations.

Item Components of device set R961008522 Mat. no. Quantity Image Page

1Differential cylinder CD70F25/16-200 with protective housing and connection facility for load unit in WS201

R961009526 1 123

2 4/3-way directional control valve 4WMM6G5X R961002550 1 106

3 Pressure reducing valve, directly operated DR6DP1-5X/ R961002544 1 113

4 Throttle check valve DRV06-1-1X/V R961002495 2 117

5 Hydraulic distributor 4x R961002485 1 134

6 Pressure gauge 0-100 bar with measuring hose R961002715 3 159

7 Hose line 630 mm R961002474 5 135

8 Hose line 630 mm with mini gauge port R961002481 2 136

The recommended accessories can be found on page 30.

14 Training Systems for Hydraulics | Study topics On/off hydraulics - manual operation according to BIBB A-H


On/off hydraulics - manual operation according to BIBB A-H

The learning objectives are coordinated with the German Federal Institute for Vocational Training (BIBB) proposed topics. The project tasks are practical and conform to a large extent with customer orders from industry and trade. The structure is planned according to didactic principles and explains the implementation of individual projects on a step-by-step basis.Delivery includes:

project manuals for instructors and trainees device set with components

Project manuals for instructors and trainees The instructor's guide to imparting know-how is available to instructors and teachers of specific subjects. This project manual contains basic theoretical knowledge and guidance on practice-related project tasks in the field of hydraulic control technology. It contains additional details about projects and information for instructors.The trainee uses the student handbook. This manual is also used to enter measurement results and calculated parameters, as well as to process characteristics. Answering of project-related issues rounds off the project exercises.

Contents: hydraulic basics related to the project exercises a practical introduction to the project exercises (identifying hydraulic

components) design of a hydraulic system (example calculation) hydraulic pump: function, pressure-flow characteristic differential cylinder function, pressure conversion, velocity,

filling volume hydraulic motor function, torque, speed, pressure differential directional valve: set-up, function, piston shapes check valve function pilot-operated check valve: function throttle valve: function, pressure differential flow characteristic throttle valve: function, supply and discharge throttling flow control valve: function, flow pressure differential characteristic direct-operated pressure relief valve / pilot-operated function,

pressure-flow characteristic direct-operated pressure relief valve: pressure level, series or parallel

connection settings pressure reducing valve: function hydraulic accumulator: function differential circuit: control of a hydraulic circuit cyclical circuit: use and system behavior commissioning, troubleshooting

Study topics | Training Systems for Hydraulics On/off hydraulics - manual operation according to BIBB A-H

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Trainer's manuals Language Mat. no. Book title Type short description Edition no.Trainer's manual On/off hydraulics - manual operation (according to BIBB) DE

DE R901385280 Schalthydraulik Manuelle Bettigung (nach BIBB)

MANUAL TW-HY-LH 201DE

DCA-DE000158

Trainer's manual On/off hydraulics - manual operation (according to BIBB) EN

EN R901385282 On/Off-hydraulics manual operation (according to BIBB)


DCA-EN000158

Trainer's manual On/off hydraulics - manual operation (according to BIBB) ES

ES R901385286 Hidrulica de conmutacin Accionamiento manual (conforme a BIBB)

MANUAL TW-HY-LH 201ES

DCA-ES000158

Trainee's manuals Language Mat. no. Book title Type short description Edition no.Trainee's manual On/off hydraulics - manual operation (according to BIBB) DE

DE R901385281 Schalthydraulik Manuelle Bettigung (nach BIBB)

MANUAL TW-HY-SH 201DE

DCA-DE000159

Trainee's manual On/off hydraulics - manual operation (according to BIBB) EN

EN R901385283 On/off-hydraulics manual operation (according to BIBB)


DCA-EN000159

Trainee's manual On/off hydraulics - manual operation (according to BIBB) ES

ES R901385287 Hidrulica de conmutacin Accionamiento manual (conforme a BIBB)

MANUAL TW-HY-SH 201ES

DCA-ES000159

No. Exercise topic BIBB exercise01 hydraulic power unit A1

02 hydraulic pump A1

03 differential cylinder (pressure conversion) B1

04 differential cylinder (flow) B1

05 hydraulic motor G2

06 4/3-way directional control valve B2

07 check valve C1

08 non-return valve, pilot-controlled C1

09 throttle valve, adjustable D1


10 throttle check valve D3

11 flow control valve D2

12 pressure relief valve (direct-operated/pilot-operated

E1/E2

13 control via pressure relief valve E1

14 pressure reducing valves E3

15 hydraulic accumulator: F1

16 differential circuit: G1

17 cyclical circuit B2/G4

18 commissioning, troubleshooting H1


16 Training Systems for Hydraulics | Study topics On/off hydraulics - manual operation according to BIBB A-H


Device set for WS200/WS290 On/off hydraulics - manual control (according to BIBB, A-H), complete



This device set is used to impart the basics of hydraulics based on project work. Only industrial components of size 6 are used that have been specially prepared for use in the training exercises. The device set matches the On/off hydraulics - manual operation training manual (according to BIBB) that deals with BIBB exercises A-H. The exercises with the listed components can be performed on both the WS200 and WS290 workstations.



R961009526 1 123

2 Planetary motor R961008748 1 128

3 4/2-way directional control valve 4WMM6C5X R961002552 1 106

4 4/3-way directional control valve 4WMM6G5X R961002550 1 106

Study topics | Training Systems for Hydraulics On/off hydraulics - manual operation according to BIBB A-H

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5 4/3-way directional control valve 4WMM6J5X R961002510 1 107

6 4/3-way directional control valve 4WMM6E5X/ R961002551 1 107

7 Pressure relief valve DBDH6G1X/ R961002520 2 113

8 Pressure relief valve, pilot-operated DB6K1-4X/50 R961002545 1 114


10 2-way flow control valve 2FRM6B36-3X/ R961002546 1 118

11 Throttle valve DRV06-1-1X/V R961002539 1 117


13 Non-return valve S6A1.X R961002489 1 121

14 Non-return valve, hydraulically pilot-operated SV 6 PB1-6X/ R961002513 1 122

15 Accumulator module R961002503 1 132


17 Shut-off valve R961002491 1 120


19 Hose line 630 mm R961002474 8 135

20 Hose line 1000 mm with 90 fitting and mini gauge port R961004330 4 138



18 Training Systems for Hydraulics | Study topics On/off hydraulics - electrical operation according to BIBB A-H and Z1-Z3


On/off hydraulics - electrical operation according to BIBB A-H and Z1-Z3

The learning objectives are coordinated with the German Federal Institute for Vocational Training (BIBB) proposed topics. The project tasks are practical and conform to a large extent with customer orders from industry and trade. The structure is planned according to didactic principles and explains the implementation of individual projects on a step-by-step basis.Delivery includes:

project manuals for instructors and trainees device sets with components

Project manuals for instructors and trainees The instructor's guide to imparting know-how is available to instructors and teachers of specific subjects. This project manual contains basic theoretical knowledge and guidance on practice-related project tasks in the field of hydraulic control technology. It contains additional details about projects and information for instructors.The trainee uses the student handbook. This manual is also used to enter measurement results and calculated parameters, as well as to process characteristics. Answering of project-related issues rounds off the project exercises.

Contents: hydraulic fundamentals related to the project exercises electronic fundamentals related to the project exercises a practical introduction to the project exercises (identifying hydraulic components) interpretation of a hydraulic system (example assessment) hydraulic pump: function, pressure-flow characteristic differential cylinder function, pressure conversion, velocity, filling volume hydraulic motor function, torque, speed, pressure differential directional valve: set-up, function, piston shapes check valve function pilot-operated check valve: function throttle valve: function, pressure differential flow characteristic throttle valve: function, supply and discharge throttling flow control valve: function, flow pressure differential characteristic direct-operated pressure relief valve / pilot-operated function, pressure-flow characteristic direct-operated pressure relief valve: pressure level, series or parallel connection settings pressure reducing valve: function hydraulic accumulator: function differential circuit: control of a hydraulic circuit cyclical circuit: use and system behavior commissioning, troubleshooting pressure switch function, hysteresis hydraulic circuits: rapid traverse/creep speed switching cycle, load-holding circuit, bridge rectifier, cyclical circuit for

high-volume flows, accumulator charging circuits

Study topics | Training Systems for Hydraulics On/off hydraulics - electrical operation according to BIBB A-H and Z1-Z3

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Trainer's manuals Language Mat. no. Book title Type short description Edition no.Trainer's manual On/off hydraulics - electrical operation (according to BIBB) DE

DE R901385278 Schalthydraulik Elektrische Bettigung (nach BIBB)


DCA-DE000160

Trainer's manual On/off hydraulics - electrical operation (according to BIBB) EN

EN R901385284 On/off hydraulics - electrical operation (according to BIBB)


DCA-EN000160

Trainer's manual On/off hydraulics - electrical operation (according to BIBB) ES

ES R901385288 Hidrulica de conmutacin - Accionamiento elctrico (conforme a BIBB)


DCA-ES000160

Trainee's manuals Language Mat. no. Book title Type short description Edition no.Trainee's manual On/off hydraulics - electrical operation (according to BIBB) DE

DE R901385279 Schalthydraulik Elektrische Bettigung (nach BIBB)


DCA-DE000161

Trainee's manual On/off hydraulics - electrical operation (according to BIBB) EN

EN R901385285 On/off hydraulics - electrical operation (according to BIBB)


DCA-EN000161

Trainee's manual On/off hydraulics - electrical operation (according to BIBB) ES

ES R901385289 Hidrulica de conmutacin - Accionamiento elctrico (conforme a BIBB)


DCA-ES000161


No. Exercise topic BIBB exercise01 hydraulic power unit A1

02 hydraulic pump A1

03 differential cylinder (pressure conversion) B1

04 differential cylinder (flow) B1

05 hydraulic motor G2

06 4/3-way directional control valve B2

07 check valve C1

08 non-return valve, pilot-controlled C1

09 throttle valve, adjustable D1

10 throttle check valve D3

11 flow control valve D2

12 pressure relief valve (direct-operated/pilot-operated

E1/E2


13 control via pressure relief valve E1

14 pressure reducing valve E3

15 hydraulic accumulator: F1

16 differential circuit: G1

17 cyclical circuit B2/G4

18 commissioning, troubleshooting H1

19 pressure switch (incl. hysteresis) E4

20 rapid traverse/creep speed control G3

21 load-holding circuit with jerk-free reduction Z1

22 bridge rectifier Z2

23 cyclical circuit for high-volume flows Z3

24 accumulator charging circuits Z3



Device set for WS200/WS290 On/off hydraulics - electrical operation (BIBB, A-H), complete



This device set is used to impart the basics of hydraulics based on project work. Only industrial components of size 6 are used that have been specially prepared for use in the training exercises. The device set is aligned with the training manual On/off Hydraulics - Getting Started, which deals with BIBB exercises A-H and Z1-Z3. The exercises with the listed components can be performed on both the WS200 and WS290 workstations.



R961009526 1 123


3 4/2-way directional control valve 4WE6C6X/ R961002547 2 109

4 4/3-way directional control valve 4WE6G6X/ R961002548 1 109


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5 4/3-way directional control valve 4WE6J6X/ R961002554 1 110

6 4/3-way directional control valve 4WE6E6X/ R961002549 1 110











17 Shut-off valve R961002491 1 120


19 Hose line 630 mm R961002474 8 135






Electrical device set for WS200, On-off hydraulics - electrical operation (BIBB A-H), excluding I/O module



To be used together with the device set on/off hydraulics - electrical operation and related project manuals.The electrical device set is intended for use at the WS200 workstation.

Item Components of electrical device set R901386157 Mat. no. Quantity Image Page

1 Control unit housing version BIBB module R961009678 1 146

2 Electrical pressure switch R961003488 1 152

3 Proximity switch, inductive R961003106 2 151

4 Solenoid cable with LED, shape A, black R900846807 2 149

5 Solenoid cable with LED, shape A, gray R900846808 1 149

6 Measurement cable set, small R900029597 1 150


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Electrical device set for WS200, On-off hydraulics - electrical operation (BIBB A-H), with I/O module



To be used together with the device set on/off hydraulics - electrical operation and related project manuals. The electrical device set is intended for use at the WS200 workstation.

Item Electrical device set R901386158 Mat. no. Quantity Image Page

1 Control unit housing version - BIBB module + I/O module R961009675 1 146








Electrical device set for WS200, On-off hydraulics - electrical operation (BIBB A-H), excluding I/O module



The electrical device set is intended for use along with the on/off hydraulics - electrical operation device set and the related manual. The electrical device set is intended for use at the WS200 workstation.


1 Control unit 19" version - BIBB module R961009676 1 147

2Adapter plate 19" version - 1 switch, IEC socket, power supply cable

R901384795 1 148







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Electrical device set for WS200, On-off hydraulics - electrical operation (BIBB A-H), with I/O module


Type short description DEVICE SET TS-HS 504-1 X

The electrical device set is intended for use along with the on/off hydraulics - electrical operation device set and the related manual. The electrical device set is intended for use at the WS290 workstation.



2 Control unit 19" version - I/O module R961009677 1 147


R901384795 1 148








Additional study topic On/off hydraulics - extension BIBB Z1-Z3

Expanded device set for WS200/WS290 for On/off hydraulics - electrical control (BIBB, Z1-Z3)



The device set is matched to the On/off Hydraulics - Getting Started training manual that deals with BIBB exercises A-H and Z1-Z3. The exercises with the listed components can be performed on both the WS200 and WS290 workstations.


1 Pressure relief valve pilot-operated DBW10A1-5X/ R961002553 1 116




Study topics | Training Systems for Hydraulics On/off hydraulics - hydraulics troubleshooting

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On/off hydraulics - hydraulics troubleshooting

Troubleshooting relates to hydraulic circuits with manually or electrically operated directional valves. The device sets are based on the contents of the BIBB device sets and deepen the subject area of commissioning and troubleshooting.The experiments provide help with acquiring practical knowledge of systematic troubleshooting. The experiments can be performed at both the WS200 and WS290 workstations.Delivery includes:

1 project folder with instructor and trainee manual Device set with manipulated components for manually operated directional valves Device set with manipulated components for electrically operated directional valves

Project manuals for instructors and trainees The following experiments are included in the troubleshooting manual:

Experiment 1: Introduction to systematic troubleshooting, orientation guide

Experiment 2: Various types of errors, adjustment errors, system errors

Experiment 3: Various combined errors, adjustment errors, system errors

The troubleshooting manual can be used with the device sets for on/off hydraulics - troubleshooting, manual operation and electrical operation. The electrical control is not explicitly described in the manual.

Instructor/trainee manuals Language Mat. no. Book title Type short description Edition no.Trainer's/trainee's manual On/off hydraulics - troubleshooting DE

DE R900054511 Fehlersuche in Hydraulikanlagen

MANUAL TW-HY-AL 204DE

RD 00261

Trainer's/trainee's manual On/off hydraulics - troubleshooting EN

EN R961003805 Fault detection in hydraulic systems

MANUAL TW-HY-AL 204EN

RE 00261

Trainer's/trainee's manual On/off hydraulics - troubleshooting ES

ES R961003954 Bsqueda de fallos en instalaciones hidrulicas

MANUAL TW-HY-AL 204ES

RS 00261

28 Training Systems for Hydraulics | Study topics On/off hydraulics - hydraulics troubleshooting


Additional study topic On/off hydraulics - extension troubleshooting manual operation

Device set for WS200/WS290 On/off hydraulics - troubleshooting, manual operation



The device set includes components with integrated defects for training setups for systematic troubleshooting in hydraulic systems.The device set is aligned with the manual On/off hydraulics - troubleshooting. The exercises with the listed components can be performed on both the WS200 and WS290 workstations.

Item Device set R961006619 Mat. no. Quantity Image Page

1 4/3-way directional control valve 4WMM6G5X manipulated R961006553 1 106

2 Pressure relief valve DBDH6G1X/100 manipulated R961006549 1 *

3 Pilot-controlled pressure relief valve DB6K1-4X/50YV manipulated R961006550 1 *

4 Non-return valve S6A1.X with hose 630 mm manipulated R961006552 1 *

5 Inspection glass R961006596 1 133

*Items 2 to 4 not available separately


Study topics | Training Systems for Hydraulics On/off hydraulics - hydraulics troubleshooting

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Additional study topic On/off hydraulics - extension troubleshooting electrical operation

Device set for WS200/WS290 On/off hydraulics - troubleshooting, electrical operation



Except for the electrically operated directional valve 4WMM6G5X (R961006553), the device set is identical with the device set R961006619.Exercise installations can be taken from the previous manual. The electrical control is not explicitly described in the manual.


1 4/3-way directional control valve 4WMM6G5X manipulated R961006551 1 *

2 Pressure relief valve DBDH6G1X/100 manipulated R961006549 1 *

3 Pilot-controlled pressure relief valve DB6K1-4X/50YV manipulated R961006550 1 *

4 Non-return valve S6A1.X with hose 630 mm manipulated R961006552 1 *

5 Sight glass R961006596 1 133

*Items 1 to 4 not available separately


30 Training Systems for Hydraulics | Study topics On/off hydraulics - Accessories


On/off hydraulics - Accessories

Measuring equipment is needed for the exercises in on/off hydraulics to measure the flow, speed and pressure. Further accessories can be found on page 64.We recommend:

Item Components Mat. no. Quantity Image Page

1 Basic measuring device set R961009563 1 155

2 Measuring glass for WS201 R961009485 1 161

or Measuring glass 2.5l for WS290 R961002564 1 166

3 Filling and test equipment for hydraulic accumulators 0538103012 1 132

4 Pressure relief coupling R961002927 1 138

Study topics | Training Systems for Hydraulics Proportional servo valve technology - proportional hydraulics

31


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Proportional servo valve technology - proportional hydraulics

In preparation for their future careers, students should work practically and largely independently and they should learn how to act in a professional context. This means that core and technical skills are taught in an integrated manner including independent planning, execution and monitoring of all practical project tasks.Delivery range:

Proportional servo valve technology project manual for instructors and trainees Device sets for WS290 proportional servo valve technology - proportional hydraulics with the components

Project manuals for instructors and trainees This manual is intended for instructors and trainers of proportional servo valve technology. Project exercises are performed at the WS290 workstation and are described in detail. The projects are based on practical examples from electro-hydraulic control technology. Trainees are expected to have a basic knowledge of hydraulics and electrics.Before the projects are executed, the previous project manuals up to On/off hydraulics - Electrical operation should have been completed. General explanations of proportional servo valve technology form the introduction to this topic.Before carrying out the project exercises, general aspects of safety and safety information indicate potential hazards.In general, the results that are documented in the manual for teachers and trainers should serve as a guide.



Numbers of the project exercises and the respective topic01 Set up cylinders with external potentiometer as command

value specification07 Set motion sequence with 4 square ramps

02 Set up cylinders with SWMA1 setpoint module as command value specification

08 Set discharge with 2 proximity switches

03 Set SWMA1 setpoint module with 4 command values 09 Set automatic discharge with 3 proximity switches

04 Set SWMA1 setpoint module with 4 command values 10 Set system pressure with external potentiometer

05 Set braking distance using proximity switch signal 11 Set up cylinders with 2 different pressure levels

06 Pressure conditions at the proportional servo valve and influence on the speed and braking distance

12 Automatic discharge with proportional servo valve

Trainer's manuals Language Mat. no. Book title Type short description Edition no.Trainer's manual Proportional servo valve technology - proportional hydraulics DE

DE R961003779 Projekthandbuch Stetigventiltechnik(Proportionaltechnik)


RD 00847

Trainer's manual Proportional servo valve technology - proportional hydraulics EN

EN R961003873 Project manual proportional servo valve technology


RE 00847

Trainer's manual Proportional servo valve technology - Proportional hydraulics ES

ES R961003872 Manual de proyecto Tcnica de vlvulas continuas


RS 00847

Trainee's manuals Language Mat. no. Book title Type short description Edition no.Trainee's manual Proportional servo valve technology - proportional hydraulics DE

DE R961003780 Projekthandbuch Stetigventiltechnik(Proportionaltechnik)


RD 00848

Trainee's manual Proportional servo valve technology - proportional hydraulics EN

EN R961003875 Project manual proportional servo valve technology


RE 00848

Trainee's manual Proportional servo valve technology - proportional hydraulics ES

ES R961003874 Manual de proyecto Tcnica de vlvulas continuas


RS 00848

Study topics | Training Systems for Hydraulics On/off hydraulics - Accessories

33


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1 Differential cylinder CD70F25/16-400 with protective housing R961003495 1 124


34/3-way proportional directional control valve 4WREE6E08-2X/ with int. elec. and load simulation

R961003533 1 111


5 Proportional pressure relief valve DBEE6-1X/50 R961003924 1 116




9 Hose line 630 mm R961002474 4 135


Device set for WS290 Proportional servo valve technology - proportional hydraulics, complete



The device set is used to impart practical examples from electro-hydraulic control technology based on project work. Only components which meet industry standards and which are specially prepared for use in the training exercises are used. The device set is aligned with the proportional servo valve technology - proportional hydraulics manual. The exercises with the listed components can be performed at the WS290 workstation.




Electrical device set for WS290 proportional servo valve technology - proportional hydraulics



To be used together with the device set proportional servo valve technology - proportional hydraulics and related project manuals.This electrical device set is intended for use at the WS290 workstation.



2Switching element 19" version - 1 switch + 2 push buttons, 3 NO contacts, 3 NC contacts

R961009617 1 139

3 Display unit 19" version - 2 displays, max. display range 0-20 V R961009623 1 141

4 Adapter plate 19" version - circular connector / lab jack R961009630 1 142

5 Command value encoder 19" version - with ramp R961009631 1 141

6 Command value encoder 19" version - +/- 10 V R961009632 1 141

Study topics | Training Systems for Hydraulics On/off hydraulics - Accessories

35


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R901384795 1 148



10 Cable, 7-pin for integrated electronics R961003550 1 151

11 Cable set for setpoint measurement R961009488 1 151

12 Measurement cable set, large R900021502 1 150

36 Training Systems for Hydraulics | Study topics Proportional servo valve technology device sets - control hydraulics


Proportional servo valve technology device sets - control hydraulics

In preparation for their future careers, students should work practically and largely independently and they should learn how to act in a professional context. This means that core and technical skills are taught in an integrated manner including independent planning, execution and monitoring of all practical project tasksDelivery range:

Analog control loop project manual for instructors and trainees Device sets for WS290 proportional servo valve technology - hydraulic control with the components

Project manuals for instructors and trainees This manual is intended for instructors and trainers of proportional servo valve technology. Project exercises are performed at the WS290 workstation.In the analog control loop project manual, practical exercises are described for understanding hydraulic control technology. These exercises are intended as an introduction to practical control technology.First, the problem of maintaining a position at different loads with an open control distance is dealt with. This makes it possible to recognize the need for and the advantages of a closed control circuit.Subsequently, components of the electro-hydraulic control circuit are presented, their structure and function are explained and basic safety instructions for performing the exercises are given.Contents of the project exercises:

1. Adjusting the position of the 4/3 directional valve 2. Adjusting the proportional servo valve 3. Position control

Trainer's manuals Language Mat. no. Book title Type short description Edition no.Trainer's manual Proportional servo valve technology - control hydraulics DE

DE R961005011 Projekthandbuch Analoger Positionsregelkreis


RD 09979

Trainer's manual Proportional servo valve technology - control hydraulics EN

EN R961005091 Project manual Analog position control loop


RE 09979

Trainee's manuals Language Mat. no. Book title Type short description Edition no.Trainee's manual Proportional servo valve technology - control hydraulics DE

DE R961005010 Projekthandbuch Analoger Positionsregelkreis


RD 09980

Trainee's manual Proportional servo valve technology - control hydraulics EN

EN R961005092 Project manual Analog position control loop


RE 09980

Study topics | Training Systems for Hydraulics Proportional servo valve technology device sets - control hydraulics

37


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Component set for WS290 Proportional servo valve technology - control hydraulics, complete



This device set is used to impart practical applications of a simple electro-hydraulic position control loop.Only components which meet industry standards and which are specially prepared for use in the training exercises are used.The device set is matched to the MANUAL Proportional servo valve technology - control hydraulics.The exercises with the listed components can be performed at the WS290 workstation.


1 Load unit, controllable, for dynamic load simulation R961004486 1 126

24/4-way closed loop control valve 4WRPEH6 with integrated electronics

R961002509 1 112











10 Hose line 630 mm R961002474 7 135



Study topics | Training Systems for Hydraulics Proportional servo valve technology device sets - control hydraulics

39


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Electrical component set for WS290 Proportional servo valve technology - control hydraulics



To be used together with the device set Proportional servo valve technology - control hydraulics and related project manuals.This electrical device set is intended for use at the WS290 workstation.



2 Operating module TS-BPS 30,0, analog controller module, 30DU R961004782 1 142


R961009617 1 139









R901384795 1 148




12 Measurement cable set, large R900021502 1 150

Study topics | Training Systems for Hydraulics Continuous valve technology - Accessories

41


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Continuous valve technology - Accessories

Measuring equipment, such as a multimeter for flow and pressure measurement, is necessary for the exercises in continuous valve technology. Further accessories can be found on page 64.We recommend:



and Measuring glass 2.5 l for WS290 R961002564 1 166

2 Gear volumetric flow sensor R961002508 1 157

and Measurement cable for ISDS R900733207 1 157

and Measuring device set 3020 R913038909 1 154

3 Multimeter VC175 R913038027 1 154


42 Training Systems for Hydraulics | Study topics Mobile hydraulics - throttle control


Mobile hydraulics - throttle control

In preparation for their future careers, students should work practically and largely independently and they should learn how to act in a professional context. This means that core and technical skills are taught in an integrated manner including independent planning, execution and monitoring of all practical project tasks.Delivery range:

Project manual Mobile hydraulics throttle control 3SM-12 for teachers and for trainees Device sets for WS290 mobile hydraulics - throttle control with the components

Project manuals for instructors and trainees The projects are based on practical examples from mobile control technology. Project exercises are performed at the WS290 workstation.It is recommended to complete each project in sequence. Trainees are expected to have a basic knowledge of hydraulics. Before the projects are executed, the previous project manuals up to On/off hydraulics - Manual operation should have been completed.Structure of the project manual:

Overview of the historical development of mobile hydraulics

Technological classifications of throttle control and its application fields on different machines

Fundamentals of mobile hydraulics in mobile working machines

Basic principles of hydraulics, throttle control and their operation, as well as explanation of special symbols

Structure and function of a 6/3 directional control valve, load holding valve, primary and secondary valve and pilot controller

Before carrying out the project exercises, general aspects of safety and safety information indicate potential hazards.

Study topics | Training Systems for Hydraulics Mobile hydraulics - throttle control

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Numbers of the project exercises and the respective topic01 Flow control and velocity control 06 Secondary valves

02 Pressure control and power control 07 Parallel operation

03 Hydraulic pilot control 08 Control characteristics

04 Speed with different loads 09 Boom lowering and force structure

05 Load holding valves

Trainer's manuals Language Mat. no. Book title Type short description Edition no.Trainer's manual Mobile hydraulics - throttle control DE

DE R961004608 Projekthandbuch Mobilhydraulik Drosselsteuerung 3SM-12


RD 09968

Trainer's manual Mobile hydraulics - throttle control EN

EN R961005094 Project manual: Mobile hydraulics throttle control 3SM-12


RE 09968

Trainee's manuals Language Mat. no. Book title Type short description Edition no.Trainee's manual Mobile hydraulics - throttle control DE

DE R961004614 Projekthandbuch Mobilhydraulik Drosselsteuerung 3SM-12


RD 09969

Trainee's manual Mobile hydraulics - throttle control EN

EN R961005093 Project manual: Mobile hydraulics throttle control 3SM-12


RE 09969

44 Training Systems for Hydraulics | Study topics Mobile hydraulics - throttle control


Device set for WS290 Mobile hydraulics - throttle control, complete



This device set is used to impart practical applications of mobile control technology. Only components which meet industry standards and which are specially prepared for use in the training exercises are used.The set is aligned matched to the Mobile Hydraulics - Throttle Control manual.The exercises with the listed components can be performed at the WS290 workstation.


1 Mobile hydraulics - throttle control 3 SM12 R961005970 1 130

2 Hydraulic pilot controller with 2 hand levers 2-2TH6 R961005967 1 129


4 Load unit 80 kg stationary R961004005 1 125

Study topics | Training Systems for Hydraulics Mobile hydraulics - throttle control

45


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7 Pressure shut-off valve, directly operated DZ6DP1-5X/ R961002558 1 114





12 Hose line 630 mm R961002474 11 135


14 Hose line 1000 mm with 90 fitting R961004331 6 137


46 Training Systems for Hydraulics | Study topics Mobile hydraulics - load sensing control


Mobile hydraulics - load sensing control


Project manual Mobile hydraulics load sensing 2M4-12 for teachers and for trainees Device sets for WS290 mobile hydraulics - load sensing with the components

Project manuals for instructors and trainees The projects are based on practical examples from mobile control technology. Project exercises are performed at the WS290 workstation.It is recommended to complete each project in sequence. Trainees are expected to have a basic knowledge of hydraulics. Before the projects are executed, the previous project manuals up to On/off hydraulics - Manual operation should have been completed.Structure of the project manual:


Technological classifications of load sensing control and their application fields on different machines


Basic principles of hydraulics, load sensing control and their operation, as well as explanation of special symbols

Structure and function of an LS control block 2M4-12, a stroke limiter, primary and secondary valves and a pilot control 2-2TH6

Study topics | Training Systems for Hydraulics Mobile hydraulics - load sensing control

47


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Numbers of the project exercises and the respective topic01 Primary pressure limitation 07 Secondary valves

02 Actuator volumes and stroke limitations 08 Load sensing pressure limitation

03 Load pressure compensation 09 Parallel operation with sufficient delivery volume

04 Pressure loss in the P line 10 Parallel operation with insufficient delivery volume

05 Hydraulic pilot control 11 Stroke cylinders with alternating directions of force

06 External power unit

Trainer's manuals Language Mat. no. Book title Type short description Edition no.Trainer's manual Mobile hydraulics - load sensing control DE

DE R961004565 Projekthandbuch Mobilhydraulik Load Sensing 2M4-12


RD 09970

Trainer's manual Mobile hydraulics - load sensing control EN

EN R961005147 Project manual Mobile hydraulics load sensing 2M4-12


RE 09970

Trainee's manuals Language Mat. no. Book title Type short description Edition no.Trainee's manual Mobile hydraulics - load sensing control DE

DE R961004564 Projekthandbuch Mobilhydraulik Load Sensing 2M4-12


RD 09971

Trainee's manual Mobile hydraulics - load sensing control EN

EN R961005146 Project manual Mobile hydraulics load sensing 2M4-12


RE 09971

48 Training Systems for Hydraulics | Study topics Mobile hydraulics - load sensing control


Device set for WS290 Mobile hydraulics - load sensing control, complete



This device set is used to impart practical applications of mobile control technology. Only components which meet industry standards and which are specially prepared for use in the training exercises are used.The device set is matched to the Mobile Hydraulics - load sensing control manual.The exercises with the listed components can be performed at the WS290 workstation.


1 Mobile hydraulics - load sensing 2M4-12 R961005969 1 131




Study topics | Training Systems for Hydraulics Mobile hydraulics - load sensing control

49


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13 Hose line 630 mm R961002474 10 135




50 Training Systems for Hydraulics | Study topics Mobile hydraulics - LIFD control


Mobile hydraulics - LIFD control


Project manual Mobile hydraulics LIFD 2SX-12 for teachers and for trainees Device sets for WS290 mobile hydraulics - LIFD control with the components

Project manuals for instructors and traineesThe projects are based on practical examples from mobile control technology. Project exercises are performed at the WS290 workstation.It is recommended to complete each project in sequence. Trainees are expected to have a basic knowledge of hydraulics. Before the projects are executed, the previous project manuals up to On/off hydraulics - Manual operation should have been completed.Structure of the project manual:


Technological classifications of load pressure-independent flow distribution (LIFD) and its application fields on different machines


Basic principles of hydraulics, load pressure-independent flow distribution (LIFD) and its operation, as well as explanation of special symbols

Structure and function of an LIFD control block 2SX-12, load pressure signal, pressure balances, consumer flow and hydraulic pilot control

Study topics | Training Systems for Hydraulics Mobile hydraulics - LIFD control

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Numbers of the project exercises and the respective topic01 Pressure adjustment and hydraulic pilot control 05 Stroke cylinders with alternating directions of force

02 Adjust actuator volumes and stroke limitations 06 Boom cylinders with external force effects

03 Effects of piping 07 Functional principle of an LIFD system

04 Effects of loads

Trainer's manuals Language Mat. no. Book title Type short description Edition no.Trainer's manual Mobile hydraulics - LIFD control DE

DE R961004654 Projekthandbuch Mobilhydraulik LUDV 2SX-12


RD 09972

Trainer's manual Mobile hydraulics - LIFD control EN

EN R961005149 Project manual Mobile hydraulics LIFD 2SX-12


RE 09972

Trainee's manuals Language Mat. no. Book title Type short description Edition no.Trainee's manual Mobile hydraulics - LIFD control DE

DE R961004749 Projekthandbuch Mobilhydraulik LUDV 2SX-12


RD 09973

Trainee's manual Mobile hydraulics - LIFD control EN

EN R961005148 Project manual Mobile hydraulics LIFD 2SX-12


RE 09973

52 Training Systems for Hydraulics | Study topics Mobile hydraulics - LIFD control


Device set for WS290 Mobile hydraulics - LIFD control, complete



This device set is used to impart practical applications of mobile control technology. Only components which meet industry standards and which are specially prepared for use in the training exercises are used.The set is matched to the Mobile Hydraulics - LIFD control manual.The exercises with the listed components can be performed at the WS290 workstation.


1 Mobile hydraulics - LUDV 2SX-12 R961005966 1 130




Study topics | Training Systems for Hydraulics Mobile hydraulics - LIFD control

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13 Hose line 630 mm R961002474 11 135




54 Training Systems for Hydraulics | Study topics Mobile hydraulics - Accessories


Mobile hydraulics - Accessories

Measuring equipment is needed for the exercises in mobile hydraulics to measure the flow, speed and pressure. Further accessories can be found on page 64.We recommend:



and Measuring glass 2.5l for WS290 R961002564 1 166






Study topics | Training Systems for Hydraulics Expansion device sets

55


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Expansion device sets

As an inexpensive complement to study topics, Bosch Rexroth offers appropriate supplementary device sets (overview on page 10). Supplementary device sets provide the perfect way to move to the next study topic using the device set from the previous one.

Expanded device set for WS200/WS290 from On/off hydraulics - getting started to On/off hydraulics - manual operation (according to BIBB, A-H)



Item Expansion device set R961009465 Mat. no. Quantity Image Page


2 4/2-way directional control valve 4WMM6C5X R961002552 1 106

3 4/3-way directional control valve 4WMM6J5X R961002510 1 107

4 4/3-way directional control valve 4WMM6E5X/ R961002551 1 107












13 Shut-off valve R961002491 1 120


15 Hose line 630 mm R961002474 3 135



Study topics | Training Systems for Hydraulics Mobile hydraulics - Accessories

57


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Expansion device set for WS200/WS290 from On/off hydraulics - manual operation to On/off hydraulics - electrical operation (according to BIBB, A-H)





2 4/3-way directional control valve 4WE6G6X/ R961002548 1 109

3 4/3-way directional control valve 4WE6J6X/ R961002554 1 110


Expansion device set for WS290 from On/off hydraulics - electrical operation (BIBB, A-H) to Continuous valve technology - proportional hydraulics




1 Differential cylinder CD70F25/16-400 with protective housing R961003495 1 124

24/3-way proportional directional control valve 4WREE6E08-2X/ with int. elec. and load simulation

R961003533 1 111

3 Proportional pressure relief valve DBEE6-1X/50 R961003924 1 116



Expansion electrical device set for WS290 from On/off hydraulics - electrical operation (BIBB, A-H) to Continuous valve technology - proportional hydraulics



Item Expansion electrical device set R901386161 Mat. no. Quantity Image Page


R961009617 1 139










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Expansion device set for WS290 from On/off hydraulics - Electrical operation (according to BIBB, A-H) + Continuous valve technology - proportional hydraulics to Continuous valve technology - control hydraulics






R961002509 1 112

Expansion device set for WS290 from Continuous valve technology - proportional hydraulics to Continuous valve technology - control hydraulics






R961002509 1 112





7 Hose line 630 mm R961002474 3 135




Expansion electrical device set for WS290 from On/off hydraulics - electrical operation (BIBB, A-H) to Continuous valve technology - control hydraulics



Item Expanded electrical device set R901386163 Mat. no. Quantity Image Page

1 Operating module TS-BPS 30.0, analog controller module, 30DU R961004782 1 142


R961009617 1 139









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Item Expansion electrical device set R901386164 Mat. no. Quantity Image Page

1 Operating module TS-BPS 30.0, analog controller module, 30DU R961004782 1 142


Expansion device set for WS290 from Continuous valve technology - proportional hydraulics to Continuous valve technology - control hydraulics





Expansion device set from On/off hydraulics - manual operation (according to BIBB, A-H) to Mobile hydraulics - throttle control




1 Mobile hydraulics - throttle control 3 SM12 R961005970 1 130

2 Hydraulic pilot controller with 2 manual levers 2-2TH6 R961005967 1 129




6 Hose line 630 mm R961002474 3 135




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Expansion device set for WS290 from Mobile hydraulics - throttle control to Mobile hydraulics - load sensing control




1 Mobile hydraulics - load sensing 2M4-12 R961005969 1 131



Expansion device set for WS290 from Mobile hydraulics - throttle control to Mobile hydraulics - LIFD control




1 Mobile hydraulics - LUDV 2SX-12 R961005966 1 130




64 Training Systems for Hydraulics | Study topics Accessories


Accessories

Flowmeters


1 Stopwatch, digital R900061256 1 155

and Measuring glass for WS201 R961009485 1 161

or Measuring glass 2.5 l for WS290 R961002564 1 166

2 Volumetric flow rate sensor 1.0 to 7.5 l/min R961002561 1 158


and Temperature sensor with ISDS R900749653 1 157



or Measuring device set 5060 R913038907 1 155

Speed measurement


1 Tachometer visual R961008893 1 156

2 Speed sensor R900892375 1 156


Study topics | Training Systems for Hydraulics Accessories

65


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Multimeter


1 Multimeter VC175 R913038027 1 154

For filling the hydraulic accumulator



Measuring sets



2 Measuring device set 3020 R913038909 1 154

3 Measuring device set 5060 R913038907 1 155

Pressure measurement


1 Digital pressure gauge R961009534 1 158

2 Pressure transmitter 0-200 bar with ISDS R900738915 1 156

66 Training Systems for Hydraulics | Study topics Accessories


Workstations | Training Systems for Hydraulics

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Workstations

68 Training Systems for Hydraulics | Workstations


Workstations | Training Systems for Hydraulics

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Contents of Workstations

Overview 70

WS200 workstation 76WS201 Hydraulic work station,single-sided for 1 - 2 trainees 76WS200 Hydraulic workstation,double-sided for 2 - 4 trainees 77WS200 Hydraulic workstation,single-sided and pneumatics for 1 - 2 trainees 78WS200 Hydraulic workstation,double-sided for 2 - 4 trainees and pneumatics 79WS201 Pneumatic workstation,double-sided for 2 - 4 trainees 80WS200 workstation, double sided component carrier 81

Extensions to the WS200 Workstation 82WS201 Hydraulic workstation, load unit measuring glass, single-sided for 1 - 2 trainees 82WS201 Hydraulic workstation, load unit measuring glass, double-sided for 2 - 4 trainees 82WS201 Hydraulic workstation, load unit, single-sided for 1 - 2 trainees 83WS201 Hydraulic workstation, load unit, double-sided for 2 - 4 trainees 83

WS290 Workstation 84WS290 Hydraulic workstation with single pump and pressure regulator, one-sided for 2 - 3 trainees 84WS290 Hydraulic workstation with double pump and pressure regulator, double-sided for 4 - 6 trainees 85

Accessories 86- General 86- for WS200 91- for WS290 91

70 Training Systems for Hydraulics | WS200 Workstation

Bosch Rexroth AG, 01.2015

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